Manufacturing Skill Rules For Sheetmetal Parts

AM2216
Method Issue : B
Manufacturing Skill Rules for Design of

Sheet Metal Parts
PURPOSE:
The document describes the recommended design practices applicable to flat, bent or formed sheet metal
parts. They must enable the definition of parts that can be obtained using standard manufacturing facilities.
This document provides:
− the representation and dimensioning conventions,
− recommended or to be avoided machining methods that impact the design of parts,
− the minimum design values.
SCOPE:
All designers of flat, bent or formed sheet metal parts for all aircraft programs.
Owner's Approval: (signed) Authorization: (signed)
Date : 10 December 2007
Name : DUPONT Michel Name : HELLARD Guy

Function : Head of ESDS Function : Head of ES
© AIRBUS S.A.S. 2007. ALL RIGHTS RESERVED. CONFIDENTIAL AND PROPRIETARY DOCUMENT.
Method_FM0400725_V1.1 Printed Copies are not controlled. Confirm this is the latest issue available through the Portal. Page 1 of 79
AM2216
Sheet Metal Parts Issue : B
TABLE OF CONTENTS
1 About this Document ........................................................................................................... 5

1.1 Background ......................................................................................................................... 5
1.2 Detailed Scope .................................................................................................................... 5
1.3 Organisation of the Document............................................................................................. 5
2 Definitions............................................................................................................................ 6
2.1 Sheet Metal Parts with the Creation of Unfolded ................................................................ 6
2.2 Formed Parts without the Creation of Unfolded (Undevelopable Part) ............................... 8
2.3 Technical Definitions ........................................................................................................... 9
3 Materials............................................................................................................................ 13
3.1 Standard Thicknesses (Regularly Stocked) ...................................................................... 13
3.2 Minimum Bend Radius ...................................................................................................... 13
3.3 K Factor............................................................................................................................. 13
3.3.1 Calculation of Flat Pattern Lengths: from the Flat Part...................................................... 14
3.3.2 Calculation of Flat Pattern Lengths: from the Outer Line .................................................. 14
3.4 Flange Unfolding: Standard Case ..................................................................................... 15
3.5 Curve Flange Ends Compensation: Specific Case ........................................................... 16
3.6 Joggle Compensation........................................................................................................ 18
3.6.1 Joggle on Flat Part ............................................................................................................ 18
3.6.2 Flange End Cross Joggle .................................................................................................. 19
3.6.3 Joggle on Web with Flange ............................................................................................... 20
3.6.4 Joggle on Web and Flange ............................................................................................... 20
3.7 Twin Joggle Compensation ............................................................................................... 21
3.8 Pipe Supports.................................................................................................................... 22
3.8.1 Design of the Unfolded...................................................................................................... 22
3.8.2 Heights Measure ............................................................................................................... 23
3.8.3 Overlength......................................................................................................................... 23
4 Design Recommendations ................................................................................................ 24
4.1 Unfolded Contour .............................................................................................................. 24
4.2 Bend Relief Cutaways ....................................................................................................... 24
4.3 Geometry of Bend Radii .................................................................................................... 26
4.3.1 Outside Geometry ............................................................................................................. 28
4.3.2 Geometry of the Web (with Opposite Flanges) ................................................................. 30
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5 Features ............................................................................................................................ 31
5.1 Flanges.............................................................................................................................. 31
5.1.1 Minimum Flange Heights................................................................................................... 31
5.1.2 Width of U and Z Sections................................................................................................. 31
5.1.3 Covered Flanges ............................................................................................................... 32
5.1.4 Flanges of Different Depths............................................................................................... 33
5.2 Formed Features ............................................................................................................... 34
5.2.1 Joggling ............................................................................................................................. 34
5.2.2 Flanged Lightening Holes.................................................................................................. 35
5.2.3 Flanged Holes with Return Flange .................................................................................... 36
5.2.4 Stiffened Cutouts (Non Circular) ....................................................................................... 37
5.3 Stamp Features................................................................................................................. 38
5.3.1 Stiffener Beads.................................................................................................................. 38
5.3.2 Circular Stamps ................................................................................................................. 38
5.4 Tooling Holes .................................................................................................................... 39
5.5 Locating Pin....................................................................................................................... 40
5.6 Distance between Features (mm) ..................................................................................... 40
6 Routing Recommendation................................................................................................. 43
Appendix 1. AIRBUS France........................................................................................................ 44
1.1 Standard Thicknesses....................................................................................................... 44
1.2 Joggle on Flat Part ............................................................................................................ 44
1.3 Joggle End Cross Joggle .................................................................................................. 45
1.4 Joggle on Web with Flange ............................................................................................... 47
1.5 Joggle on Web and Flange ............................................................................................... 49
1.7 Minimum Flange Heights................................................................................................... 53
1.8 Width of U and Z Sections................................................................................................. 54
1.9 K Factor for Legacy Programs (Families A320, A300, A330-A340, A380)........................ 57
1.10 Pipe Support Unfolded ...................................................................................................... 57
1.11 Bend Relief Cutaway ......................................................................................................... 58
1.12 Distance between Particularities ....................................................................................... 58
Appendix 2. AIRBUS Deutschland............................................................................................... 60
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2.9 K Factor............................................................................................................................. 65
Appendix 3. AIRBUS UK.............................................................................................................. 66
Appendix 4. AIRBUS España....................................................................................................... 76
Table of References ................................................................................................................... 77
Table of approval ........................................................................................................................ 78
Record of Revisions.................................................................................................................... 79
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1 About this Document

The document is dedicated to the designers who want to do some flat, bent or formed sheet
metal parts.
The drawing content is not specified. For drawing content, refer to the standard drawings.
All A/C programs are concerned by this document. For each program, refer also to the
General Reference Structure Design Principles document, which gives general design
recommendations and rules to be satisfied for optimum definition of structural parts.
The purpose is to guide the designer in his choices and to give the methods and rules to
ensure the manufacturing feasibility.
This document describes the recommendations for the sheet metal part design and the rules
to calculate the unfolded.
Designers from all the Airbus sites should use this document as a guideline.
1.1 Background
The sheet metal design process (see AP2657) must be applied. The implementation
domain is the same that the aircraft programs cited above.
For the CATIA V5 method, see the AM2263.
1.2 Detailed Scope

The information inside this Airbus Method is doing the link between design principles and
detailed CAD model of the Geometrical Reference Mock-up in the frame of the design
manufacturing.
These rules are to be considered as advises or recommendations from manufacturing to
designers in order to design part which are the easiest to manufacture. These recommendations
deal with general cases only. In case of special need of design or manufacturing, the solutions
have to be discussed in integrated program teams between design, stress and manufacturing in
order to make a common decision that satisfies all conditions.
The method presents transnational rules, but also NatCo specific rules. All these exceptions
are reported and noticed in the body of the Method for each rule.
1.3 Organisation of the Document

This chapter is general information about the document.
The second chapter "Definitions" describes the different type of sheet metal parts.
The third one defines the material characteristics.
The fourth one concerns the design recommendations, and more particularly the shape of the
part.
The fifth one lists the different rules to respect for each feature.
The sixth one gives a few advices on the routing recommendation.
The annexes give a view of the different design recommendations from the different AIRBUS
sites organized by appendixes.
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2 Definitions
2.1 Sheet Metal Parts with the Creation of Unfolded

− Flat parts:
Parts made from thin sheet metal by routing and requiring no forming.
− Bent parts:
Parts made from thin sheet metal by routing with only straight bend lines at constant
angles and excluding all other forming processes (joggling, flanged cutouts, stiffener
beads).
The outer contour of the part is machined before the folding phases.
The sheet is positioned on a standard V block; the bend is made as the male form
tool descends. Some standard dies are used.
Angle obtained depends on the distance through which the male form moves.
P↓
Die
Minimum
flange
height
Part with straight bends
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− Formed parts:
Parts made from thin sheet metal by routing with at least one curve fold line and/or a
forming operation (joggling, flanged cutouts, beads) requiring the making of a form
tool excluding undevelopable parts from a reference face (stamped or drawn parts).
The dies used are specific.
The outer contour of the part is machined before the forming phases.
Cold forming process consists of:
• the contour routing of the flattened part,
• the positioning of the flattened part on special tools,
• the forming by fluid cell presses or rubber presses.
The developed is based on expert rules, but sometimes the result is not exact.
Minimum
flange
height
Part with flanged hole and curve flange Pipe support (with curve flange)
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2.2 Formed Parts without the Creation of Unfolded (Undevelopable Part)

Parts containing deep forming. No unfolded is required.
The outer contour of the part is machined after the forming basing on the 3D.
Example of technology used: SPF (Super Plastic Forming)
Panels are out of scope
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2.3 Technical Definitions

− Unfolded:
The unfolded is the representation of the bent part in flat mode.
− Flange height:
Section plane
normal to the
folding curve
FLANGE
Flange
height
WEB
Web:
The web of the part is basically the reference face of the part regarding its function and its way
of manufacturing (it is most of the time the most important flat or nearly flat surface of the part).
NB: if doubt exists, contact the Manufacturing site.
USE CASES ILLUSTRATIONS
1 - U shaped parts, it is the

central surface,
Web
Web
Web
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USE CASES ILLUSTRATIONS
2 - L or C shaped parts it is
the most important surface
Web Web
• Ω shaped parts, it is usually

the central surface to
ensure symmetrical
behaviour
Web
• The web is not always the
biggest face
4 - Z Shaped parts, it is when

surfaces are clearly
different the most
important surface.
Otherwise, it is the
assembled surface
Web
Web
− Compensation:
Following a folding or formed phase, the material is distorted. To define the unfolded,
compensation has to be applied. In case of the location for the production of the part
is known, the designer may define the compensations agreed with the manufacturing.
Even if the compensations could be modified by the manufacturing later in the
process.
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− Internal bent angles:
Internal angle
Outer angle
Outer line
T: sheet metal thickness

Ri: internal bend radius
K: The K factor corresponds to the position of the neutral fiber from the inner bend.
This parameter is used to calculate the flat pattern.
K*T
Ri
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− Joggle:
J: Joggle depth
JR: Joggle run-out
JR
J
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3 Materials
This chapter describes the material behaviours and the rules to calculate the unfolded.
3.1 Standard Thicknesses (Regularly Stocked)

The materials are in the process of harmonisation. Please refer to the different sites as:
− AIRBUS France (A-F): see Appendix 1.1.
− AIRBUS Deutschland (A-D): see Appendix 2.1.
− AIRBUS United Kingdom (A-UK): see Appendix 3.1.
− AIRBUS España (A-E): see Appendix 4.1.
3.2 Minimum Bend Radius

− For AIRBUS France, see NSA 4550.
− For AIRBUS Deutschland, see DIN 9003 refer material cross reference list 75-T-0-
003-0-0 or TN10007 or HSB (Handbuch Strukturberechnung).
− For AIRBUS UK, see AP 2-050-00.
− For AIRBUS España, see I + D-P-212.
3.3 K Factor
K parameter is used to calculate the flat pattern.
For all material, thickness, angle or other, the Airbus common Kfactor = 0.4.
The manufacturing can change the Kfactor value according the type of flange and the machine
capabilities.
Only for tricky area (see example below): the K-factor must be tested in a range of 0.2 - 0.5 to
ensure that manufacturing can change the Kfactor value without having problem on the folded
part.
Tricky area
(see chapter 4.1
"Unfolded Contour")
For A-F, specific K factor: See appendix 1.9 for legacy programs
For A-D, see appendix 2.9
There are two methods to calculate the flat pattern lengths.
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3.3.1 Calculation of Flat Pattern Lengths: from the Flat Part

L
B
A T
α A B
R: bend radius
L = A + B + (180 - α).(π/180).(R + K.T)

α: angle in degrees
3.3.2 Calculation of Flat Pattern Lengths: from the Outer Line

W
F T
α
Outer line
R: bend radius
F-S W
S: shrinkage
L=W+F-S
S = 2(R + T).tg ((180 - α)/2) - (π/180).(R + K . T).(180 - α)
α: angle in degrees
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3.4 Flange Unfolding: Standard Case

Flange ends and hole points are unfolded according to a plane, which is normal to the outer
line and coincident to point.
The corner radiuses are kept as on 3D model.
Normal plane to the

outer line and coincident
to the hole point
Unfolded
Outer line
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3.5 Curve Flange Ends Compensation: Specific Case

A compensation on the curve flange end can be applied on specific demand from Design
office or Manufacturing.
Example of treatment in case of pilot holes on a curved flange.
In the case of an hole-to-hole assembling process the result of the functional cotation can lead
to a very accurate hole positionning on the blank.
The experience shows that good results are performed with the following method.
The methods is used for parts such as cleats, slat ribs, assembled with an hole-to-hole
method.
Curved distance between holes on the unfolded model = curved distance between holes on
the 3D model.
Tooling holes
Edge
distance
Edge Curve distance A

distance on the 3D model
Curve distance B on the 3D model
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Specific case
Flange end
compensation
Edge distance
Edge distance
Curve distance A'
on unfolded
Curve distance B'

Flange end on unfolded
compensation
The holes positions on the unfolded model are computed in order to get B' = B.
The distance A' = A, allows to locate the first hole. We deduce the flange end compensation by
the respect of the distance to edge.
This method is coming from experimental results and is deployed only in case of small needed
tolerances on pilot holes.
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3.6 Joggle Compensation

The material behavior during the forming phase should be taken into account to calculate the
unfolded. In case of the location for the production of the part is known the designer may
define the compensations agreed by the manufacturing else the compensations must be
defined by the manufacturing later in the process.
For each following type of joggle, the compensations are defined as below:
3.6.1 Joggle on Flat Part

X+A
X A
− AIRBUS-France: see Appendix 1.2.

− AIRBUS-Deutschland: see Appendix 2.2.
− AIRBUS-UK: see Appendix 3.2.
− AIRBUS-España: see Appendix 4.2.
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3.6.2 Flange End Cross Joggle
Rb
Af Xf JR
Rc
J
Ra
a b
WEB

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3.6.3 Joggle on Web with Flange

3.6.4 Joggle on Web and Flange

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3.7 Twin Joggle Compensation
Rb Rb
Ra
Flange
b a a b
Web
JR
J
Xcj

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3.8 Pipe Supports
3.8.1 Design of the Unfolded

Classic developed of pipe support:
12 mm min between
radii run-out
Design (with cutting of the last flange):

In the case where the return flange is cut, ensure that the modifications done on the
unfolded are transferred to the 3D model.
Pipe: external diameter (D)

90°
∅ ≥ L (see chapter 4.1

"Unfolded Contour") Return flange
h
Hi H
20 mm 20 mm
maxi X > 0 mm maxi Note: In case of large pipe diameters, more than
two "20 mm width lugs" may be necessary to
hold the pipe.
These lines go by the pipe center
Manufacturing recommendation: Hi ≥ 16 mm for D > 30 mm, but can be smaller for the
smallest pipe support diameters.
AIRBUS-France: in case of modifications on parts from legacy programs, the use of the
method of the Appendix 1.10 is authorized.
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3.8.2 Heights Measure
Pipe: external diameter (D)
h - S + Overlength
H-S External folded

lines (outer lines)
To define S: see chapter 3.3.2 "Calculation of Flat Pattern Lengths: from the Outer Line".
3.8.3 Overlength
PIPE DIAMETER AIRBUS FRANCE AIRBUS AIRBUS AIRBUS
DEUTSCHLAND UK ESPAÑA
D < 38 mm 1,5 mm 0 0 0
38 ≤ D < 96 1 mm 0 0 0
D ≥ 96 0 0 0 0
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4 Design Recommendations
4.1 Unfolded Contour

Re
Ri
L
For problems related to weight savings, protection or fatigue strength, it is strongly

recommended to cut corners on the contour with radii (Re and Ri).
In order to decrease the manufacturing cost, the common values are advised.
ALUMINIUM STEEL AND TITANIUM
RE RI L RE RI L
Standard values (mm) ≥6 ≥ 8.1 ≥ 16.1 >2 >2

> 0.3
Minimum value (mm) 2 2.1 4.1 1 1
4.2 Bend Relief Cutaways

The bend relief cutaway is the material removal area where two flanges intersect.
This chapter describes the minimum values to respect according to the cut out shape.
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BEND LINE FORMED PART
1) Angle between bend lines α < 90°

Recommendation 1
Width
X of 20
web
α
20
Flat section limits Ri
Flat section
limits
Definition of the width X according to the flange
heights:
HEIGHT OF 8 12 18 24 28 34 36 ≤ 52 > 52 Recommendation 2
THE SMALLEST
FLANGE
X min 12 14 16 18 20 22 24 2/3H H+10
2) Angle between bend lines α ≥ 90° 20

Ri
Recommendation 1 (favourite solution) Flat section
limits
Ri
2 mm min
Recommendation 3
α
Flat section
limits
Ri
Recommendation 2
Flat section 2 mm
L limits mini
Ri
2 mm min Recommendation 4
α L refer to § 4.1
"Unfolded Contour"
Flat section
limits
Ri
2 mm mini
L: Refer to previous chapter 4.1 "Unfolded Contour". Flat section
limits
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4.3 Geometry of Bend Radii

Note: Whenever possible, routing must cut the bend line perpendicular.
In this chapter, α is the flange side angle.
α < 45°
Re
Developed flange
α
Flat section limits
45° ≤ α < 90°

• Favourite solution
Developed flange
Re α
Flat section limits
Centre of radius above

flat section limits
• Recommandation
Developed flange Flat section limits

α
Re
Centre of radius between

flat section limits
α = 90°
Developed flange
Flat section limits
AM2216
α > 90°
• Favourite solution
α Developed flange
Ri
The centre of the radius is

above the flat section limits
• Recommendation
The following solution is a quite expensive manufacturing solution, as some rework can be
needed on the part.
The blend-in radius can bite
into the bend radius
α
Developed flange
Ri
Virtual median line to illustrate

that whenever it is possible,
the center of the Ri radius
must be in the "above area" of The centre of the radius is
the flat section limit space between the flat section limits
AM2216
Specific case:
Recommendation 1
• Favourite solution:
The centre of radius is below the flat section limits.
Flat section limits X
Ri
X ≥ 0, this relation must always be right
Recommendation 2:
The following solution is a quite expensive manufacturing solution as some rework can be
needed on the part.
Avoid when possible (expensive solution)

Ri
Centre of radius is between the flat section limits.

→ Risk of crack initiation.
4.3.1 Outside Geometry

− Classic flanges
Take the flange height value (H) recommended by the minimum flange heights table
(refer to the chapter 5.1.1 "Minimum Flange Heights"). This may cause no manual
rework.
Re
For α < 45°
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α
H
α = flange side angle
− Flange with progressive height

Unfolded of a bent part
Limits of flat part
Developed flange
Avoid progressive height when possible

on bent part (expensive solution)
No problem if formed part
Specific cases:
Take value H = height according

to heights in corresponding min
height table
Take the flange height value (H) recommended by the minimum flange
heights table (refer to the chapter 5.1.1 "Minimum Flange Heights").
L H
H 6 8 10 12 16 20 25 32 40 50 63
L mini 20 25 32 40 50 63 80 100 125 160 200
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4.3.2 Geometry of the Web (with Opposite Flanges)

Recommendation 1 Recommendation 2
(favourite solution)
Re
Ri
Web area Web area
Re
Ri
Centre of blend-in radius is Centre of blend-in radius can be

on the web area outside of the web area
α < 45°
This blend-in Radius
can be same as
bend radius
AM2216
5 Features
This chapter defines the recommendations specific to the feature geometry.
Definition of feature:
Geometric characteristics defining the sheet metal part (holes, flanges, joggle, others).
5.1 Flanges
5.1.1 Minimum Flange Heights

For parts with straight bend lines and curve bend lines, take the height of the largest flange
according to tables below. If flange height less than table value is needed an arrangement with
manufacturing is necessary.
H
R: Bend radius
First of all, the designer must choose the material and the thickness.
Following the chapter 3.2 "Minimum Bend Radius" the bend radius is defined.
When all information are available, the designer can choose the flange height.
5.1.2 Width of U and Z Sections

Sizes of the part are constrained by the Manufacturing capabilities.
− For bent and formed parts:
• AIRBUS-France: see Appendix 1.8.
• AIRBUS-Deutschland: see Appendix 2.8.
• AIRBUS-UK: see Appendix 3.8.
• AIRBUS-España: see Appendix 4.8.
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5.1.3 Covered Flanges

There are two principles:
− by covered flange (no protection treatment on the covered surface, because the
protection is done after the folding process),
− by added square (requires an assembly, with protection treatment ensured).
L: Refer to previous chapter 4.1 "Unfolded Contour".
Covered lug
L min
Outer angle >90° Outer angle < 90°
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Added square:
Brace
5.1.4 Flanges of Different Depths

Use case: Joggle on straight flange
Manufacturing recommendation:
Joggle on flange Cutting on flange (favourite solution)

→ Saving: light industrialisation (no specific die)
AM2216
X>0
Flat section limits
L: Refer to previous chapter 4.1 "Unfolded Contour".
5.2 Formed Features
5.2.1 Joggling
For the joggle definition, refer to the documents see below:
− For AIRBUS France, see ASN453-01
− For AIRBUS Deutschland, see DIN29548-2
− For AIRBUS UK, see AP2-050-00
− For AIRBUS España, see DIN29548-2
There shall be no fastener on the joggle run-out.
Whenever possible, joggles should be made at 90° to the flange (as recommendation 1, see
below).
R
R
J T
1 mm min Run-out
JR
JR: joggle run-out
Recommendation 1 (favourite solution):
Joggle at 90°
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90°
Recommendation 2:
In case of problem to position the fastener, then use an inclined joggle with an angle of 30° or 60°.
Angle
5.2.2 Flanged Lightening Holes

Flanged lightening holes reduce weight, are easy to produce, induce a little stiffness to webs,
and provide access. Inspection flanges should all be the same way to assist tooling and their
direction should facilitate drainage.
Flanged lightening holes are preferred in the thickness range of 0,7 mm - 2,0 mm.
If possible, position the flanges holes in the same direction as the flanges on the item. Two
cut-off edge holes precision can be considered:
− Standard cut-off edge holes
− Precision cut-off edge holes
− For AIRBUS France, see ASN451-01 ("trou de precision" to use, except specific
case)
− For AIRBUS Deutschland, no local standard available
− For AIRBUS España, see ASN451-01
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5.2.3 Flanged Holes with Return Flange

If possible, position the flanged holes in the same direction (see below, the flanges are
oriented in Z+).
− For AIRBUS France, not used
− For AIRBUS Deutschland, see LN9007
− For AIRBUS UK, not used
− For AIRBUS España, see AEN 16070
Detailed view:
AM2216
5.2.4 Stiffened Cutouts (Non Circular)

− Take a radius greater than or equal to R min of flanged lightening holes in the
following table:
MATERIAL Z10CNT18 5086 CLAD 2024
ANGLE α 80° < α ≤ 120° α > 120° 80° < α ≤ 120° α > 120°
HEIGHT MIN HEIGHT MIN HEIGHT NORMAL EXCEP- HEIGHT MIN HEIGHT NORMAL EXCEP- HEIGHT MIN
H RADIUS H RADIUS H MIN TIONAL H RADIUS H MIN TIONAL H RADIUS
R R RADIUS MIN R RADIUS MIN R
R RADIUS R RADIUS
R R
6 39 33 6 22 6 50 40 6 25
8 61 55 8 30 8 75 60 8 35
10 76 65 10 43 10 95 78 10 52
TBD TBD 12 92 75 12 110 85
16 150 120 16 175 125
20 185 145 20 220 150
28 340 260 28 375 260
− Take a flange height greater than or equal to the minimum flange height.
R min as
per table
H
Note: Flanged cutouts must be positioned in same direction as the majority of flanges on the
part.
If α > 90° then the minimum value for H can be decreased (consult manufacturing to
ensure o the part feasibility).
Stiffened cutouts
H
α
Bend
radius
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5.3 Stamp Features
5.3.1 Stiffener Beads

− For AIRBUS France, see ASN451.05 and NSA 451.06
− For AIRBUS Deutschland, see tan11588
− For AIRBUS España, see ASN451.05
Bead stamping direction must be the same that the bent flanges (see section B-B).
Stiffener beads will be positioned perpendicular to bent flanges.
B
Section B-B
90°
Flange and
C C stamping direction
t Section C-C
Note: For cost reasons, straight and parallel beads will be preferred to circular beads.
5.3.2 Circular Stamps

If possible, position the stamps in the same direction as the flanges.
− For AIRBUS France, not used
− For AIRBUS Deutschland, see LN9006
− For AIRBUS UK, not used
− For AIRBUS España, not used
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5.4 Tooling Holes

The designer defines the position of the tooling holes.
Many sheet metal components require tooling Holes for Press-Forming and Hand routing
purposes. In that case manufacturing can use all the diameters between 0 and the diameter
proposed by the design.
In case of use of tooling hole for positioning parts during assembly process a specific note
must appear on the drawing: "Tooling hole used during assembly process".
Wherever possible these should be positioned on the web and arranged in an asymmetrical
fashion ensuring adequate clearance.
Adequate distances with cut outs, bend radii, contour and others should be respected.
− The normal diameter values are defined below.
A-F A-D A-UK A-E
Tooling Holes diameter 5.1 6.1 4.85 5.1

6.1 (preferred by
the Manufacturing)
No tooling holes are required for SPF technology parts.

Tooling holes are required for:
− all curved bend line part,
− all straight bend line parts with non parallel flanges,
− all parts with stamped features and/or joggles,
− tooling holes are necessary on part with three flanges on the web,
− on specific Manufacturing request.
If it is not possible to position tooling holes on the part, production department can provide
external lugs, which are removed after use although this inevitably leads to increase
production costs.
Choosing position and quantity of Tooling Holes (TH) for attachment during forming.
− When part web length < 560 mm: a minimum of 2 THs as far away from each other as
possible, is indispensable on the reference face during each forming operation.
− When part web length > 560 mm: a minimum of 3 THs,
− The part must have only one position on the die during forming to avoid positioning
errors (foolproofing)
− Distance between THs must be balanced.
− Parts with curved bend lines may require more THs to limit displacement of material
during forming.
− Minimun distance between 2 Tooling holes: 22 mm
− Maximum distance between 2 Tooling holes: 300 mm
Note: In the specific zones (e.g. waterproof zone), not to make tooling holes and precise it on
the drawing.
AM2216
5.5 Locating Pin

The locating pin is necessary to avoid confusion on the parts nearly symmetrical.
Locating pin
120 118
5.6 Distance between Features (mm)

Min distance
Flat section limits
GEOMETRICAL BEND FLANGED STIFFENER INNER OUTSIDE TOOLING

PARTICULARITIES HOLES BEADS CONTOUR CONTOUR HOLES
CUTOUT
Bend 18 18 15 6
Flanged holes 18 18 18 15 15 6
Stiffener beads 18 18 Min 2 bead 15 Min 2 bead 6
widths widths
Inner contour 15 15 15 15 15 10
cutout
Outside contour 15 Min 2 bead 15 10
widths
Tooling holes Please refer to the following pictures
AM2216
• Minimum distance between TH and routing

contour:
10
TH fastener, i.e. 10 mm 10
• Minimum distance between TH and a DO hole
of Ø ≤ 5.1 mm:
→ 1st choice: TH fastener = 10 mm
→ 2nd choice: DO hole fastener as per NSA 10
5419
• Minimum distance between TH and a DO hole
of Ø > 5.1: to DO hole fastener
DO hole fastener
Note: Tooling Holes (TH)
Design Office Holes (DO)
DO hole fastener
Distance from Tooling Holes to:

− a flange,
− a flanged hole,
− a stiffener bead,
− a flanged cut-out.
10 min
Usual minimum distance: 10 mm
AM2216
− Distance between tooling hole and C-flange (only for AIRBUS-Deutschland):
AM2216
6 Routing Recommendation
Internal radii should be as large as possible, this dictates the cutter size used at minimum
diameter of 12.0 mm and hence the production economies achieved (cutter speeds, feeds,
and stack height).
All external corners should be radiused due to the difficulty of producing square corners and
as a weight saving measure.
Principle to be retained for the heights of inner cut-out flanges:
− Heights are reduced in curve sections regarding the minimum flange height.
Ri > 12 mm
H min
Corners
If the previous routing recommendation is not possible, then in order to design a part that can
be manufactured, the designer have to keep in mind the he has to increase the angle of 90°
flanges in rounded sections to 135° or 120° (by reducing height if possible).
When the designer has some problems to design this solution, he can highlight by a nota
stating that the angle of 90° flanges in rounded sections is increased to X value 120° and the
height is reduced to the value Y.
Example:
from 120° to 90°
Area developing
90°
120°
90°
Curved section
Area developing from
120° to 90°
AM2216
Appendix 1. AIRBUS France
1.1 Standard Thicknesses

The designer has to choose a material referenced by the material and processes department.
From a manufacturing point of view, the following materials are easier to implement:
PRIORITY PART TYPES ASNA (ABS) DESIGNATION
1 Pipe supports ASNA 3044 5086 H 111

1 Bent parts ASNA 6098 2024 T4 HF clad
(ABS5503A)
1 Formed parts ASNA 3042 2024 F clad
(ABS5044H)
2 Flat and Bent parts ASNA 3012 2024 T3 clad
(ABS5044D)
For all materials:
STANDARD THICKNESSES
0.4 0.5 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.5 3 3.2 3.5 4
1.2 Joggle on Flat Part

Table defining developed part elongation values (A)
THICKNESS 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.5 3 4
JOGGLE
0.8 to 1 0.21 0.19 0.19 0.15 0.14 0.13 0.12 0.11 0.1 0.09 0.07
1.1 to 1.5 0.4 0.35 0.3 0.3 0.27 0.25 0.24 0.22 0.18 0.15 0.13
1.6 to 2 0.5 0.5 0.4 0.4 0.39 0.37 0.36 0.3 0.28 0.23 0.22
2.1 to 3 0.9 0.8 0.7 0.7 0.70 0.65 0.65 0.6 0.5 0.4 0.37
3.1 to 4 1.3 1.2 1.1 1.1 1.05 1 0.34 0.9 0.8 0.7 0.6
4.1 to 5 1.6 1.6 1.4 1.3 1.3 1.3 1.3 1.3 1.1 0.9 0.7
5.1 to 6 1.9 1.8 1.6 1.6 1.6 1.5 1.5 1.6 1.5 1.2 1
6.1 to 7 2.2 2.1 1.9 1.9 1.9 1.8 1.9 1.8 1.7 1.5 1.3
7.1 to 8.5 3 2.9 2.6 2.5 2.5 2.5 2.5 2.5 2.4 2 1.8
8.6 to 10 3.5 3.4 2.9 2.9 2.8 2.8 2.8 2.7 2.6 2.3 2.2
10.1 to 12 4 3.9 3.8 3.8 3.8 3.8 3.5 3.7 3.6 3.2 3
AM2216
1.3 Joggle End Cross Joggle

The compensation is only applied on the smallest length of flange ends.
− Flange end cross joggle X ≤ 3 JR
2 JR X Internal joggle
R12 A
J
Flange
R12
JR
Web
2 JR X External joggle
A
R12
R12
JR
For legacy programs (families A320, A300, A330-A340, A380): this design is allowed
Flange end cross joggle X ≤ 50 mm
X
R12 A
S = 3.5 ASN 453.01
R12
AM2216
− Flange end cross joggle X > 3 JR

2 JR 3 JR Internal joggle
R12
J
Flange
JR
X
Web
2 JR 3 JR External joggle
R12
JR
X
Flange end cross joggle X > 50 mm
X > 50
R12 S = 3.5 ASN 453.01
AM2216
1.4 Joggle on Web with Flange

− Joggle on web with flange X ≤ 3 JR
R12
J
Flange
R12
Web
JR
X + A/2
R12
R12
JR
X + A/2
AM2216
− on web with flange X > 3 JR

Internal joggle
R12 2 JR 3 JR
J
Flange
Web
JR
X
R12
JR
X
AM2216
1.5 Joggle on Web and Flange

− Joggle on web and flange X ≤ 3 JR
2 JR X A Internal joggle
R12
J on Flange
J on Web
Flange
Web
JR
X+A
2 JR X A J on Flange External joggle

R12
J on Web
JR
X+A
Note: If there is an internal joggle on web and an external joggle on flange, or vice versa; the
compensations of joggle depths are opposed.
AM2216
− Joggle on web and flange X > 3 JR
R12
J on Flange
J on Web
Flange
Web
JR
X
2 JR 3 JR J on Flange External joggle

R12
J on Web
JR
X
AM2216

− L ≤ 6 JR
Unfolded
Flange
Web
JR JR
− L > 6 JR
2 JR 3 JR 3 JR 2 JR
Unfolded
Flange
Web
JR JR
Specific cases: with different joggle depths
− L ≤ 6 JR
2JR
2JR
Unfolded
Flange
Web
JR JR
AM2216
− L > 6 JR
2JR 3JR 3JR 2JR
Unfolded
Flange
Web
JR JR
• If distance between joggles is ≤ 100: draw a continuous line
≤ 100
• If distance between joggles is > 100: draw 50 mm lines

50 50
AM2216
1.7 Minimum Flange Heights

THICKNESS BEND RADIUS α ≤ 80 H MINI 100 ≤ α
(MM) (MM) (MM)
80 < α < 100
2 t = 0.8 7 5.3 6
0.4
2.5 t = 1 7 5.3 6
2t=1 7 5.4 6
0.5
2.5 t = 1.25 7 5.4 6
2 t = 1.2 7.5 5.5 6
0.6
2.5 t = 1.5 7.5 5.5 6
2 t = 1.6 7.5 6 6
0.8
2.5 t = 2 7.5 6 6
2t=2 9.5 6.5 6
1
2.5 t = 2.5 9.5 6.5 6
2 t = 2.4 10 8 7
1.2
2.5 t = 3 10 8 7
2 t = 2.8 12 8 8
1.4
2.5 t = 3.5 12 8 8
2 t = 3.2 13 10 8
1.6
2.5 t = 4 13 10 8
2 t = 3.6 19 12 10
1.8 2.5 t = 4.5 19 12 10
3 t = 5.4 19 13 10
2t=4 19 12.5 12
2 2.5 t = 5 19 12.5 12
3t=6 19 13.7 12
2 t = 4.4 20 14 13
2.2 2.5 t = 5.5 20 14.2 13
3 t = 6.6 20 14.4 13
2t=5 24 16.8 14
2.5 2.5 t = 6.75 24 17.1 14
3 t = 7.5 24 17.4 14
2t=6 30 20 15
3 2.5 t = 7.5 30 20.5 15
3t=9 30 21 15
2 t = 6.4 30 20.2 15
3.2 2.5 t = 8 30 20.9 15
3 t = 9.6 30 21.5 15
AM2216
1.8 Width of U and Z Sections

Manufacturing feasibility of bent parts with U and Z sections.
THICKNESS BEND RADIUS L MINI (MM) U SHAPE WITH A Z SHAPE
REGARDING HEIGHT OF 20 MM L MINI (MM)
H MINI L MINI (MM)
2 t = 0.8 12 18.3 7
0.4
2.5 t = 1 12 18.5 7 H
2t=1 12.1 18.6 7.1
0.5 L
2.5 t = 1.25 12.1 18.8 7.1
L
2 t = 1.2 12.2 18.7 7.2
0.6
2.5 t = 1.5 12.2 18.9 7.2
2 t = 1.6 13.2 18.8 8.6
0.8
2.5 t = 2 13.2 19 8.6
2t=2 14 19. 11
1
2.5 t = 2.5 14.2 19.2 11.2
2 t = 2.4 14.2 20 12.1
1.2
2.5 t = 3 14.2 20 12.3
2 t = 2.8 14.2 22.8 13.8
1.4
2.5 t = 3.5 14.2 23 14
2 t = 3.2 16.5 24 17
1.6
2.5 t = 4 16.5 24.2 17.2
2 t = 3.6 19 24.5 18.2
1.8 2.5 t = 4.5 19 24.7 18.8
3 t = 5.4 19.3 24.9 19.2
2t=4 20 24.7 20.8
2 2.5 t = 5 20 25 21
3t=6 20.4 25.2 21.2
2 t = 4.4 20.2 24.9 21.4
2.2 2.5 t = 5.5 20.3 25.2 22.2
3 t = 6.6 20.6 25.7 23
2t=5 22.5 26 24.4
2.5 2.5 t = 6.75 25 30 25.8
3 t = 7.5 27.4 33 27.1
2t=6 26 26 27.5
3 2.5 t = 7.5 30.5 28.5
3t=9 35 29
2 t = 6.4 26.5 27.7
3.2 2.5 t = 8 31 28.8
3 t = 9.6 35.5 29.5
AM2216
Particular case
Bend 1 and 2
Length maxi 130 mm

Length maxi 100 mm
Bend 3 and 4
H
180
160
140 R = 2.5 then L equal or superior to 14

R = 3 then L equal or superior to 14,4
R = 3.5 then L equal or superior to 17
R = 4 then L equal or superior to 17
120 R = 5 then L equal or superior to 20.3
Specific tool
100
H
80
Classical
60 bending
process
40
20
0
0 20 40 60 80 100 120 140 160 180 200
L
AM2216
− For formed parts

L : Tool width
h: Internal height
h: Internal height
of the part
H: Tool height
of the part
10 mm
10 mm
l :Bottom tool width : 20 mm

mini
Maximum press size: 1180 x 3220

Maximum tool height: 110
In order to respect the 20 mm value for the width of the tool bottom (l), and in order to respect
the resistance constrains, the designer must ensure the following values.
MINIMUM TOOL MAXIMUM H VALUE FOR MAXIMUM H VALUE FOR
WIDTH L U-PART REGARDING THE L-PART REGARDING THE
(U -PART) MINIMUM TOOL WIDTH MINIMUM TOOL WIDTH
40 80 100
− For legacy programs (families A320, A300, A330-A340, A380), this design is allowed
Width of U-section
BENT PARTS FORMED PARTS
Definition of U-section widths versus flange heights Minimum width of flat section = 17 mm
Height of
H smallest
r side of U-
section
L
Width of U-section
17 min
HEIGHT
(MM) ≤ 120 ≤ 52 > 52
MIN WIDTH
(MM) L ≤ 24* L ≥ 2/3H H +10
AM2216
BENT PARTS FORMED PARTS
* For values L ≤ 24 mm, the two bends are made

at the same time with one tool.
These widths must therefore be standardised to

limit the number of tools.
L 16 18 20 22 24
1.9 K Factor for Legacy Programs (Families A320, A300, A330-A340,

A380)
For legacy programs (families A320, A300, A330-A340, A380), the parts modified or re-
designed must be unfolded according to the ASN 45502.
For information: CAD utility "Calculate devel" calculates the distance between the bend line
and the flange edge.
1.10 Pipe Support Unfolded

designed can be unfolded according to the method see below.
For Overlength: see § 3.8.2 Heights Measure
Values of H and h are generally
H = 15 mm and h = 8 mm
h
AM2216
1.11 Bend Relief Cutaway

designed can use the methods see below.
Angle between bend lines ≥ 90°
Priority 1 Priority 3
Example:
RI RI
1 mini 1 mini
Limites partie plane Limites partie plane
Priority 2 L Priority 4
L
RI RI
1 min 1 min
Flat section limits Flat section limits
1.12 Distance between Particularities

Min distance
Flat section limits
AM2216
"ITEMS" + REF. FLANGED STIFFENER FLANGED INNER OUTSIDE • BEND

CUTOUT BEAD CONTOUR CONTOUR CONTOUR • JOGGLE
(FLAT SECTION (FLAT SECTION (FLAT SECTION CUTOUT (FLAT SECTION
GEOMETRICAL LIMIT) LIMIT) LIMIT) LIMIT)
PARTICULARITIES
+ REF.
• Flanged hole Limit 1: 32

18 15
(Flat section limit) Limit 2: 18
Min Min
• Stiffener bead Limit 1: 32
2 bead 2 bead 32
widths widths
• Flanged cutout Limit 1: 32

32 32 32 32
• Inner contour
15 32 15 15 15
cutout
Limit 1 28.5 28.5 28.5 28.5

Tooling
Limit 2 13.5 13.5 13.5 13.5 13.5 13.5
hole
Limit 3 6 6 6 10 10 6
AM2216
Appendix 2. AIRBUS Deutschland

For Aluminium, Titanium and Steel:
(mm) MATERIAL (mm)

T ABS ABS ABS ABS 3.3214 MBB ABS 3.4374 3.7024.1 3.7034.1 1.4544.9 T
5044A, 5503A 5044C 5032 T4 N6020 5077A, T651
5043 3.4377
T761
0.3 X X 0.3
0.4 X X X X X 0.4
0.5 X X X X 0.5
0.6 X X X X X X X X 0.6
0.8 X X X X X X X X X 0.8
1.0 X X X X X X X X X 1.0
1.2 X X X X X X X X X X X 1.2
1.4 X X X X X X X X X 1.4
1.5 X X X 1.5
1.6 X X X X X X X X X X 1.6
1.8 X X X X X X X 1.8
2.0 X X X X X X X X X X 2.0
2.2 X X 2.2
2.4 X X 2.4
2.5 X X X X X X X X 2.5
2.8 X X X 2.8
3.0 X X X X X 3.0
3.2 X X X X 3.2
3.5 X 3.5
4.0 X X X X X X 4.0
4.4 X 4.4
5.0 X X X X X X 5.0
6.0 X X X 6.0
AM2216

No Joggle compensation. Will be calculated as two bends.
AM2216
AM2216

No special compensation for twin joggles. Will be calculated as two separate joggles.

Min flange height = thickness + bend radius + 5 mm.

HEIGHT: H (MM) ≤ 52 > 52
Height of Min width: L (mm) L=H H + 10

H smallest side
r
of U-section
L
Width of
U-section
AM2216
− For formed parts:

Whenever it is possible L ≥ H
H max = 140 mm
If L < H:
H H/L < 1.5 must be always right
Angle 90:
THICKNESS MATERIAL - CONDITION BENT RADIUS L
0.8 0; W; F 1.2 9.0

0.8 Txx 2.5 10.0
1.0 0; W; F 1.6 9.5
1.0 Txx 3.0 10.5
L
1.2 0; W; F 2.0 10.0
1.2 Txx 4.0 13.0
1.4 0; W; F 2.0 10.0
1.4 0; W; F 3.0 12.5
1.4 Txx 5.0 16.5
1.6 0; W; F 2.5 11.0
1.6 0; W; F 3.0 13.0
1.6 Txx 5.0 18.0
AM2216
Angle 45:
THICKNESS MATERIAL - CONDITION BENT RADIUS L
0.8 0; W; F 1.2 5.5

0.8 Txx 2.5 6.0
1.0 0; W; F 1.6 5.5
1.0 Txx 3.0 10.5
1.2 0; W; F 2.0 6.0
L
1.2 Txx 4.0 6.5
1.4 0; W; F 2.0 6.5
1.4 0; W; F 3.0 7.0
1.4 Txx 5.0 11.0
1.6 0; W; F 2.5 7.0
1.6 0; W; F 3.0 7.0
1.6 Txx 5.0 11.0
2.9 K Factor
The following K-Factors can be also used instead of the common K-Factor.
Aluminium = 0,35
Steel = 0,447
Titanium = 0,447
AM2216
Appendix 3. AIRBUS UK

Commonly used aluminium thicknesses for A-UK as shown in the table see below, other
materials and thicknesses are available if needed. See AP 2-050-00 or ABP 6-3201.
(MM) MATERIAL
THICKNESS L109 & L166

ABM 1-7067
0.9 X
1.2 X X
1.4 X
1.6 X
1.8 X
AM2216
Joggle compensation Calculation
Figure Taken from: - BAC Loft Instruction Sheet 5-6-2: Joggles- Formulae
AM2216

The compensation is only applied on the smallest length of flange ends.
− Flange end cross joggle X ≤ 3 JR
R12 A
R12
JR
A
R12
R12
JR
AM2216
− Flange end cross joggle X > 3 JR

R12
JR
X
R12
JR
X
AM2216

− Joggle on web with flange X ≤ 3 JR
Internal joggle
R12 2 JR X
R12
JR
X + A/2
R12
R12
JR
X + A/2
AM2216
− Joggle on web with flange X > 3 JR
R12 2 JR 3 JR Internal joggle
JR
X
R12
JR
AM2216

− Joggle on web and flange X ≤ 3 JR
2 JR X A Internal joggle
R12 J on Flange
J on Web
JR
X+A
2 JR X A J on Flange External joggle

R12
J on Web
JR
X+A
AM2216
− Joggle on web and flange X > 3 JR
R12
J on Flange
J on Web
D
D
JR
2 JR 3 JR J on Flange External joggle

R12
J on Web
JR
AM2216

− L > 6 JR ( Adjust Flattened Profile for height)
2JR JR 3JR 3JR JR 2JR
D
D
D Unfolded
Flange
Web
− L > 6 JR (Blend Flattened profile height across twin joggle)

2JR JR JR 2JR
Unfolded
Flange L
Web

The following are the minimum flanges for ease of manufacture:
T (MM)
0.45 0.55 0.70 0.90 1.20 1.60 2.00 2.50
F MIN (MM)
8 8 10 11 13 15 18 20
Where Smaller Flanges are desirable figure (b) is recommended.
(a) Recommended Minimum Flange (b) Minimum Flange
Smaller flanges may be specified on agreement with the Manufacturing facility and the design
office. A 90° Flange may not be possible smaller than specified in the above table and will
result in the flange angle being relaxed by 15° or more.
AM2216
4.0 mm MIN 6.25 mm MIN
AM2216
Appendix 4. AIRBUS España

See I + D-P-212 A.

No compensation in the Design office.






No constraint.
Note: For further information, see ASDM 05048 "Sheet Metal Design Principles".
AM2216
Table of References
DOC REFERENCE TITLE
AM2263 Sheet Metal Part - General Modeling Method

AP2265 Design to Cost Process
AP2657 Sheet Metal Design Process
ASDM 05048 Sheet Metal Design Principles
RSDP Reference Structure Design Principles (one per new A/C program)
Local reference documents
80-T-32-1000 Forming of Aluminium Sheets and Sections
80-T-32-1005 Forming of Ti and Ti-Alloy Sheets
80-T-32-2310 Production of Joggles at AI-Sections
80-T-32-5000 Superplastic Forming of Ti and AI Alloys
ADET 0064 Aluminium alloys superplastic forming
ADET 0161 Superplastic forming of titanium alloys
ADET 0196 Forming and rectification of aluminium alloys by rolling
ADET 0237 Forming and rectification of metallic materials by three points bending
AEN 16070 Lightening holes in metallic sheets
AP 2-050-00 Sheet Metal Work
ASN 451.01 Cutoff Edge Holes
ASN 451.05 Beads, Stiffening: for Machine Forming
ASN 453.01 Joggles
DIN 29548-2 Durchsetzungen
DIN 9003 Biegen von Blechen und Bändern aus Leichtmetallen
I + D-P-212 Conformado y enderezado del aluminio y sus aleaciones
IPDA 42-00 Généralités sur le formage des tôles et des profiles en alliage d'aluminium
IPDA 42-03 Cold stretch forming of rolled sheets
IPDA 42-05 Bending of aluminium alloy sheets
LN 9006 Blindprägen
LN 9007 Bördellöcher
MP 40-51-10 Forming titanium and its alloys
MTS 058 Superplastic forming
NSA 2110 General Manufacturing Tolerances
AM2216
DOC REFERENCE TITLE
NSA 451.06 Stiffening Beads

NSA 4550 Sheet Metal, Bending
S 03 Standard Flanged Lightening Hole
S 89 Swages - Stiffening - Closed
Tan 11588 Sicken für Gummiformteile nur nach Anwendungsbeispiel
Table of approval
NAME FUNCTION
AUTHORING
MUNARI Fabrice MDT-Vision for ESDK (A-F)
TREMOUREUX Laurent TNSV3
CANTERO Antoine ESDS
HOPPE Guenter TRBT13

APPROVAL
ROBOAM Michel MM
CHIVERS Peter ESD
MARTINEZ ESPEJO Avelino IES
AM2216
Record of Revisions
ISSUE DATE EFFECT ON REASONS FOR REVISION
PAGE PARA
A Sep 2004 Initial issue.

B Sep 2007 Method applicable for all A/C programs.
Sharing rules between RSDP and AM2216.
If you have a query concerning the implementation or updating of this document, please contact
the Owner on page 1
For general queries or information contact:

Airbus Documentation Office address:
Airbus - 31707 Blagnac CEDEX - France

e-mail: airbus.documentation-office@airbus.com
This document and all information contained herein is the sole property of AIRBUS S.A.S. No intellectual property
rights are granted by the delivery of this document or the disclosure of its content. This document shall not be
reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its
content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not
constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the
supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof.

Manufacturing Skill Rules For Sheetmetal Parts

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Manufacturing Skill Rules For Sheetmetal Parts

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AM2216

Manufacturing Skill Rules for Design of

Owner's Approval: (signed) Authorization: (signed)

Date : 10 December 2007

Name : DUPONT Michel Name : HELLARD Guy

1 About this Document ........................................................................................................... 5

2.4 Joggle on Web with Flange ............................................................................................... 62

1 About this Document

1.2 Detailed Scope

1.3 Organisation of the Document

2.1 Sheet Metal Parts with the Creation of Unfolded

Part with straight bends

2.2 Formed Parts without the Creation of Unfolded (Undevelopable Part)

Example of technology used: SPF (Super Plastic Forming)

Panels are out of scope

2.3 Technical Definitions

1 - U shaped parts, it is the

USE CASES ILLUSTRATIONS

• Ω shaped parts, it is usually

4 - Z Shaped parts, it is when

− Internal bent angles:

T: sheet metal thickness

3.1 Standard Thicknesses (Regularly Stocked)

3.2 Minimum Bend Radius

3.3.1 Calculation of Flat Pattern Lengths: from the Flat Part

L = A + B + (180 - α).(π/180).(R + K.T)

3.3.2 Calculation of Flat Pattern Lengths: from the Outer Line

3.4 Flange Unfolding: Standard Case

Normal plane to the

3.5 Curve Flange Ends Compensation: Specific Case

Edge Curve distance A

Curve distance B on the 3D model

Curve distance B'

3.6 Joggle Compensation

3.6.1 Joggle on Flat Part

− AIRBUS-France: see Appendix 1.2.

3.6.2 Flange End Cross Joggle

− AIRBUS-France: see Appendix 1.3.

3.6.3 Joggle on Web with Flange

− AIRBUS-France: see Appendix 1.4.

3.6.4 Joggle on Web and Flange

− AIRBUS-France: see Appendix 1.5.

3.7 Twin Joggle Compensation

− AIRBUS-France: see Appendix 1.6.

3.8 Pipe Supports

3.8.1 Design of the Unfolded

Design (with cutting of the last flange):

Pipe: external diameter (D)

∅ ≥ L (see chapter 4.1

These lines go by the pipe center

3.8.2 Heights Measure

Pipe: external diameter (D)

H-S External folded

4.1 Unfolded Contour

For problems related to weight savings, protection or fatigue strength, it is strongly

Standard values (mm) ≥6 ≥ 8.1 ≥ 16.1 >2 >2

4.2 Bend Relief Cutaways

BEND LINE FORMED PART

1) Angle between bend lines α < 90°

X min 12 14 16 18 20 22 24 2/3H H+10

2) Angle between bend lines α ≥ 90° 20

4.3 Geometry of Bend Radii

Flat section limits